Power Module Board Retention Layout for Vibration-Resistant Packaging
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Solution Overview
Problem
Existing power conversion devices for electrified vehicles face challenges in reducing size and cost while maintaining vibration resistance, particularly due to the need for rigid connections that increase the size of the base member and hinder the miniaturization of components.
Innovation Solution
A power conversion device design featuring power modules with semiconductor chips arranged side by side, a board placed between the modules with a resin-based retention member providing insulation and mechanical retention, and module terminals extending through holes in the retention member to connect with the board, eliminating the need for gaps between modules and reducing the overall size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the board is directly fixed to the base member, then vibration resistance of the board and components is ensured, but the size of the base member increases
Solution Approach 1:
A board retention member made of resin is introduced as an intermediary component between the board and the power modules. This retention member has through holes that allow module terminals to penetrate and connect to the board, while the retention member itself provides mechanical support and vibration resistance. The resin material provides insulation property and allows compact integration without increasing base member size.
Solution Approach 2:
The board retention member combines multiple functions: mechanical retention of the board, vibration damping, electrical insulation, and structural support. By merging these functions into a single component rather than using separate fixation structures, the overall device size is reduced while maintaining vibration resistance.
2Reliability
If a sufficient gap is provided between power modules for boss fixed portions, then the board can be fixed to meet vibration specifications, but the mounting area increases
Solution Approach 1:
The board retention member serves as a mediator that enables board fixation without requiring gaps between power modules. The retention member is positioned in the space between the board and power modules, with through holes that allow terminal penetration. This eliminates the need for boss fixed portions on the cooler surface, allowing compact module arrangement.
Solution Approach 2:
Instead of providing fixation space in the horizontal plane (gaps between modules), the solution moves the fixation mechanism to the vertical dimension by using a retention member that extends between the board and power modules. This allows three-dimensional utilization of space rather than requiring two-dimensional clearance.
3Reliability
If additional fixation structures are added to retain the board, then vibration resistance is improved, but the device complexity and cost increase
Solution Approach 1:
The board retention member is designed as a universal component that serves multiple functions: mechanical retention, vibration damping, electrical insulation, and structural support. This multi-functional design eliminates the need for separate fixation structures, reducing device complexity and cost while maintaining vibration resistance.
Solution Approach 2:
The retention member is made of resin material that combines mechanical strength for structural support with insulation properties for electrical safety. This composite material approach allows a single component to replace multiple specialized components, simplifying the overall device structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration ensures vibration resistance of the board and components while minimizing the device's size and cost by eliminating the need for additional fixation structures, allowing for a more compact and cost-effective power conversion system.
Implementation Method 1
the board retention member being made of a resin member having insulation property
Data Source
AI summary
This power conversion device includes: a plurality of power modules; a board which is placed at the plurality of power modules with a space provided between the board and the second surfaces, and is electrically connected to module terminals; and a board retention member which is placed in the space between the board and the plurality of power modules and retains the board, the board retention member being made of a resin member. The plurality of power modules are arranged side by side in a direction parallel to third surfaces. Each module terminal protrudes from at least one of the second surface of the power module, the third surface of the power module, and a fourth surface opposite to the third surface, and then extends toward the board. A part of the module terminal extending toward the board penetrates a through hole that the board retention member has.